Structural building unit



Sept. 22, 1931. J. H. MAGEE STRUCTURAL BUILDING UNIT Filed Aug. 21, 1929 2 Sheets-Sheet l gwwmtov a a v Sep 22, 1931. J. H. MAGEE 1,824,091

STRUCTURAL BUILDING UNIT Filed Aug; 21, 1929 2 Sheets-Sheet 2 swam riot JHM/IGEE l qf g wx Patented Sept. 22, 1931 Jenn n. menu, or CARTHAGE, MISSOURI srmicrnna BUILDING UNIT Application filed August 21, 1929.. erial No. 387,423.

This invention relates to structural buildmg units.

The advantages to be gained bymeans of composite reinforced concrete building structures, and structures employing insulating material in conjunction with cement or other cementitious material and-steel or other reinforcing material are well known The provision of such a structurehowever has been *arried' out in a rather crude and inefficient manner at the place where the material is used, andthe workhas been done with high priced skilled labor which has added to the cost of the structures, out of proportion to the advantages gained, thereby limiting the usefulness of structures of the character referred to. I

For example the advisability of using sheet cork, which is one of the best heat insulating materialsknown to the building industry, in connection with a steel reinforcing structure, is well understood in the building trades, but its use has been accomplishedonly with the greatest difficulty. Building cork, if loosely compressed to retain the highest possible heat insulating efficiency, possesses little or no structural strength, and accordingly is made up in relatively small pieces. In order to em ploy this material in connection with the building of walls, floors, partitions, etc..it is necessary to erect a supporting frame structure for the cork insulation, after which reinforcement is attached directly to the same or by some furring means Plasteris thenapplied, and must be allowed to harden, after wnichthe frame structure must be carefully removed.- The operation is thenrepeated on the opposite side of the insulation. The whole operation-is so tedious andexpensive to render the cost thereof prohibitive. illllllPOl'tflllt objectof, the present inventionis to provide a building nnitwhich may he completed at the factory, and shipped in relatively large sizes for use in forming wallsfloors, roofs, partitions and the like wherein the unit is selfcontained and self supporting to a very great; extent, and enibodies the features of having heat and sound means therefor,- and wherein the reinforcing means serves the additional function of pro viding holding means for a layer or layers of cementitious material applied to one or both faces of the unit.

A further object is to provide a novel building unit of the character referred to which is adapted to be used in connection wi h cementitlous material applied thereto whereby the finished structure will possess a high degree of tensile and compression strength, and which acts eficiently as a sound and heat insulating buildingstructure.

A further object is to provide a building unit of the character referred to wherein the metallic reinforcing means serves to adequately protect the insulating material from injury during handling and transportation.

A further object is to provide a unit of the character referred to wherein the metallic reinforcing is so positioned with relation to the insulating material that the finished structure may embody .a layer of cementitious material which substantially entirely surrounds the elements constituting themetallic reinforcement, thereby materially increasingthe structural strength of thefinished wall or other structure.

A further object is to provide a composite semi-completed building unitembodying a sheet or sheets of heat insulating material and a sheet or sheets of. metallic reinforcing of cementitious material applied to the unit after the latter has been, placed, 1n des red position.

A further object is to provide a structure of the character referredto which isparticularly adapted for use in connection with reinforcing means in'the'f form of metallic reinforcement of theeXpa-nded meta-l type, and wherein the inherent characteristics of the reinforcement are employed for assisting in bonding thec'ementitious material to the metallic reinforcing means.

A further object is to provide a struc ture which embodies inherent characteristics in connection with sheet cork as the heat insulating material whereby the advantages of such material may be used and wherein the usual disadvantage of such material because of its inherent structural weakness is of no importance.

A further object is to provide a building unit which lends itself readily to use in the building of walls, hangars, floors, partitions and the like, and which is particularly adapted to be varied in its structure and arrangement of parts to increase its utility in connection with such various uses.

A further object is to provide a semifinished composite unit embodying heat and sound insulating material and metallic reinforcing means of such nature that the adjacent units used in constructing a wall or the like will be efiiciently bonded together in the body of cementitious material applied thereto so as to impart to the finished wall or other structure substantially the same structural strength as if the wall had been initially built as a single unit.

A further object is to provide a building structure wherein the metallic reinforcing means has substantially its entire body spaced from the layer of insulating material so as to permit the metallic reinforcing means to be substantially entirely bonded in the body of cementitious material.

A further object is to provide a semi-finished structural unit adapted to be used for forming reinforced concrete constructions without the use of insulating material, where the latter is of no importance, and to provide a structure which possesses a high degree of tensile and compression strength in proportion to the thickness of the finished structure.

I Other objects and advantages of the invention will become apparent duringthe course of the following description.

' In the drawings I have shown several embodiments of the invention. In this showing,

Figure 1 is a side elevation of one of the units,

Figure 2 is a detail transverse sectional view showing the method of connecting two adjacent units,

Figure 3 is anenlarged fragmentary sectional view taken vertically through a portion of one of the units,

Figure 4 is a section similar to Figure?) 7 showing a modified form of the invention,

Figure 5 is a side elevation of a unit of the type illustrated in Figure 4,

Figure 6 is a section,

Figure 7 is a detail view similar to Figure 3 illustrating a further modification,

Figure 8 is a fragmentary side elevation of a modified form of the invention, and

Figure 9 is a detail sectional view of the same included in a finished structure.

Referring to Figures 1, 2 and 3, the numeral 10 designates a layer of heat insulating material of any suitable kind, such as natural or manufactured wood, lumber, cork, or the like. As previously stated, the present invention is particularly adapted to employ cork as the heat insulating means, and the inherent structural weakness of such material is of no importance. As will become apparent, the relatively small pieces of sheet cork which are commercially available are employed in end to end and edge to edge relation to make up an insulating unit of the proper size according to the desired size of the completed structural unit being manufactured. The individual cork sheets are preferably staggered with relation to each other, as illustrated in Figure 1.

Metallic reinforcing means in the form of expanded metal 11 is employed adjacent opposite sides of the layer of insulating material, but it will become apparent that the metal may be employed at one side of the wall.

if desired. It is preferred, however, that the metal be employed at both sides of the wall in view of the advantages to be gained thereby, such as greater inherent strength in the finished unit and structure, protection of the layer of insulation during shipment, etc.

As is Well known, the usual expanded metal is formed with a substantially diamondshaped mesh, and comprises angular strands 12 defining the diamonds and connected by solid bridges 13. Both the strands and the bridges are angularly arranged, and in assembling the structure, the strands and bridges are so arranged that they slope inwardly toward the insulation, as indicated in Figure 3, for a purpose to be described.

The metallic reinforcing sheets are preferably secured to the insulation 10 in spaced relat1on thereto, as shown in Figure 3, although other means to be described may be employed. Referring to Figure 3 the numeral 14 designates a transverse shank having a deformed central portion 15 mounted in the body of the heat insulating material 10 to mechanically and frictionally engage the same to hold it in the desired spaced relation to the metal. In the present instance the de formed portion of the shank is illustrated as being in the form of threads. The connecting shanks 14 are arranged at spaced intervals throughout the area of the sheet 10, and the outer ends of the shanks are spotwelded to certain of the bridges 13. In this connection. it will be noted that the complete sheets of metal at opposite sides ofthe structure are preferably arranged in registration so that each end of each shank 14 may be welded to bridge portions of the metal. The completed structure is adapted to receive opposite layers 6. The stamping of the bridges 20 is accomplished wi hout distorting the body of the she-ct, the four strands 18 diverging from each bridge 20 being stretched to permit the offsetting of the bridge and they form a rigid four point bracing element to maintain the position and inegrity of the reinforcing sheets when joined as shown. In this connection it will be noted that the bridges 20 and the diverging strands which have been stretched in the manner referred to, are not distored from their usual angular position, and accordingly each bridge 20 contacts with the sheet of insulating material 10 only at its inner edge. I

It willbe apparent that the greater portions of the sheets of metal 1'? lie in planes spaced from and parallel to the insulating material 10, each bridge 20 being stamped from the .plane of the sheet in the same manner and the same distanceso as to secure the parallel relationship referred to. Substantially U-shaped metal clips 21 are employed for securing the bridges 20 to the insulating material 10. These clips are referably pointed at bo h ends as at 22, (see *igure 4).

The body of each clip extends around a bridge 20 at one side, then through the insulating material 10, and the points are turned around a bridge 20 at the other side and then into the insulating sheet 10. The I completed structural unit illustrated in Figures 4, 5 and 6 also is adapted to receive a layer or layers of cementitious material 23.

The fornrof the invention illustrated in Figure 7 is par icula-rly adapted for certain uses such as in floors,-roofs, and the like wherein it is essential that one side of the finished structure be greatly reinforced to increase the compression strength while the concrete is being placed and then taking the tensile strains after the, structure is completed. In this form of the invention, a sheet of insulating material 24 is employed which i similar to he insulating materlal previously described. A metallic reinforcing structure 25 is arranged at one side of the sheet, and is similar in form to the reinforcing structures previously referred to. At the opposite side of the structure a second me allic reinforcing unit 26 is employed, which is arranged a substantial distance from the adjacent surface of theinsulating material 24.

inforcing units to the insulaing sheet also is illustrated, but the securing means previously described may be employedif desired. This is particularly true of the securing means 14 illustrated in Figure- 3.

Referring to Figure 7 it will be noted that the securing means comprises a metallic clip 27 which, when the structure is assembled, includes an intermediate straight shank portion 28. One end of the clip is turned about a bridge of the reinforcement 25, as indicated at 29, and the extremity of the clip lies against the adjacent surface of the sheet 24 as indicated at 30. The opposite end of the clip is i turned as at 31 about a bridge of the reinforcement 26 to form atie and to prevent outward movement thereof. The last named end of the'clip then curves as at 32, and has its extremity turned as at 33 and lying against the adjacent surface of the sheet 24. It will be apparent that the clip is adapted to hold the elements of the semi-finished unit in proper position with respect to each other and it is understood that bending of the metal clips ll) may be done in any manner to accomplish these results. Cementitious material 34 also is adapted to be applied against opposite sides of the unit illustrated in Figure 7 Referring to Figure 2, it will be noted that novel means is employed for bonding a number of the structural units into a completed Wall or similar structure. It will be noted from Figures 1 and 2 that each metallic reinforcing unit projects beyond the sheet of in- 3m sulating material, and as previously described, both the strands and the bridges of the metal are inclined. It has been found that if the metal is extended beyond the sheet 10 to the extent of one-half the Width and T depth of the outermost diamonds of the metal, or to the extent of one complete diamond when joined together, such extending portions will nest Within the corresponding portions of the adjacent sheets'as indicated as at 35 in Figure 2, and there will be no perceptible bulge or projection at the overlapping portions of the metal. Accordingly, when the cementitious material is applied, such material will eflicientlybond together the reinforcing units of adjacent sheets, thfls forming a wall or similar structure having all the advantages of a unit construction.

Y The form of the invention illustrated in Figures 8 and 9 is employed Where heat and -l sound insulation is of no importance. and it body 36 is employed in the form' of metallic lathing, or any other suitable openwork metallic structure. The lathing is flanked on opposite sides by sheets of expanded reinforcing metal 37, and since such reinforcing ele-i spaces between the metaland the sheet of in. V a base to which mortar may be applied.

ments are similar to the corresponding elements illustrated in Figures 5 and-6,. they need not be referred to'in detail. As illustrated, certain of the bridgesof the reinforcing sheets37 are offset inwardly as at 38 to contact with the body 36, and the offset bridges are preferably connected to the body 36 by suitable connecting wires 39. It will be apparent however, that any othersuitable connecting means may be employed.

The operation of the building unitswill be apparent from the foregoing description. As previously stated, the problems-involved in building insulated reinforced walls on the ob are such as to render the work tedious and Su'BZiPSHSlVQ as to be prohibitive. According to the aresent invention, the sheets of rein forcing material are arrangedagainst oppositesides of the sheet of insulating material and are secured thereto andtheretlirough according to either of the various means described. Thus the sheets of reinforcing material and the insulating material are secured in proper relative positions according to the character according to their use. If the units are to be employed for forming partitions, for exam- )lQ, they are vertically arranged as illustrated. and cement or other comentitious material applied against the opposite sides thereof. in the form of the invention illustrated'in Figures 1 and 3, each entire metallic structure is spaced from and arranged parallel to the layer of insulating material, and thusexcept merely for the shanks 14, all of the strands and bridges of each metallic sheet will be wholly embedded in the comentitious material, which is adapted to entirely fill the spaces bet-ween the reinforcing metal and the insulating material, and to be built up outwardly ofthe building unit to any desired thickness according to the use to which the structure is to be put.

In connection with the 'application of the 'cementitious material, attention is invited to the fact that the units are arranged in vertical position when used for partitions, walls and the likeyand under such conditions, the inclination of the strands 12 and bridges 13 is downwardly and inwardly toward thesheet 10 and thus the plastic or semifluid cementitious material is assisted in its inward movement toward the sheet 10 to entirely fill the adjacent-sheets causes such overlapped portions to be wholly embedded in and bonded 7 with the concrete or other cementitious material, and thus' the finished structure possesses substantially the same structural and tensile strength as does a unitary construction.

The operation of the form of the invention illustrated in Figures 4, 5 and 6 is substantially the same asin the form previously described, and need not be referred to in detail. It will be noted however, that only the lower edge portion of each bridge 20 contacts with the sheet of insulating material, and thus the metallic portion of the structure will be almost wholly surrounded by and embedded in the cemeiititious material applied against opposite sides of the unit.

The form of the invention illustrated in Figure 7 is particularly adapted for use in a floor slab or other unit which must stand transverse strains applied from one side of the structure. For example, if the structure illustrated is employed in a floor slab, the metal reinforcing 26 is arranged at the bottom of the structure and its spacing from the other elements of the structure greatly adds '55 to the inherent strength'of the floor.

It will be apparent that metal of any desired gauge may be employed, and it is preferred to e pl y, n most instances, the heavier gauges of metal with large mesh openings due to the economy of its useand the increased tensile strength of the resulting structure. It also will be apparent that metal of different sized mesh may be employed at opposite sides of a unit. For ex- 0 ample, the structure illustrated in Figure 7 may be provided with a relatively light metallic element 25 and relatively heavy metal 26.

It will be apparent that the units described form an integral part'of the insulated build ing structureand when initially placed in position they act as forms against which the cementitious material may be applied. The

finished structure possesses high efiiciency as izo structure lends itself readily for use in connection with stucco walls, in which case the outer face of the structure is adapted to receive concrete to the desired thickness, which is permitted to harden, whereupon it forms The inventive idea embodied in the structure illustrated in Figures 8 and 9 is the same as in the forms previously described, except that it is adapted for use in forming a completely bonded metal reinforced construction where heat and sound insulation is of no importance. The provision of the central body 36 and the spaced reinforcing elements 37 forms a semifinished unit of substantial thickness, and When concrete or other cementitious material is applied to opposite sides of the structure, the material bonds completely through the meshes of the central body 36, as Well as through the meshes of the reinforcing elements 37. It has been found that great tensile and compression strength may be provided in proportion to the thickness of the resulting Wall or other construction.

It is to be understood that the forms of my invention herewith shown and described are to be taken as preferred examples of the same and that various changes in the shape, size, and arrangement of parts may be resorted to without departing from the spirit of the invention or the scope of the subjoined claims.

I claim:

1. A building unit comprising a central body, a metallic reinforcing element arran ed at each side of said body, and fastening means each securing said elements to each other through said body and for spacing said elements from said body throughout the greater portion of their areas, said securing means being arranged at spaced points to prevent relative movement between said body and said reinforcing elements.

2. A building unit comprising a central body, an open-work substantially rigid metallic reinforcing element arranged adjacent each side of said body and at least coextensive therewith, and means arranged at a plurality of spaced points for substantially positively securing said elements to each other and to said body and operative for spacing said elements from said body throughout the greater portion of their areas.

3. A building unit comprising a central body, a relatively rigid expanded metal reinforcing element arranged adjacent each side of said body and substantially coextensive therewith, each reinforcing element including strands and bridges all inclined in the same direction toward said body, and means extending through said body at a plurality of spaced points for substantially positively attaching said reinforcing elements to each other and to said body and for supporting said elements with the greater portions thereof arranged in spaced parallel relationship to said body.

4. A building unit comprising a body of sound and heat insulating material of relatively low structural strength, a relatively rigid expanded metal reinforcing element arranged adjacent one side of said body and substantially coextensive therewith, and a plurality of spaced attaching elements hav? ing portions extending-entirely through and embedded in said. body and other portions positively connected to said reinforcing element to substantially rigidly support the lat ter in spaced parallel relation to said body.

'5. A building unit comprising a body of sound and heat insulating mate-rial of relatively low structural strength, a relatively rigid open-work metallic reinforcing element arranged on each side of said body, and an attaching element arranged at each of a plurality of spaced points, said attaching elements extending entirely through said body and positively connecting said reinforcing elements to each vother and to said body,

6. A building unit comprising a body and a relatively rigid expanded metal reinforcing element connected "to said body at spaced points in parallel spaced relation to said body, said reinforcing element having angularly arranged strands and bridges and pro? jecting beyond at least one edge of said body whereby the projecting portions of the reins forcing element of an adjacent unit are adapted to interlock therewith with the .overlapping strands and bridges in fiat contact with each other.

7; A building unit comprising a central body, a relatively rigid expanded metal reinforcing element of relatively large mesh arranged adjacent each side'of said body, and means passing through said body for attaching said reinforcing elements to each other and to said body at a plurality of spaced points to support said elements with the greater portions thereof arranged in spaced parallel relation to said body, said elements including angularly arranged strands and bridges projecting beyond at least one edge of said body to overlap the projecting portions of the reinforcing elements of an adjacent unit having similarly arranged strands and bridges whereby the overlapping strands and bridges will coincide and lie fiat against each other.

8. A building unit comprising a body of sound and heat insulating material of relatively low structural strength, a relatively rigid open-work metallic reinforcing element arranged on each side of said body, and a plurality of attaching elements arranged at spaced points throughout the area of said body and extending entirely therethrough, each attaching element having a deformed portion intermediate its ends embedded in said body and having its ends positively secured respectively to said reinforcing elements.

9. A building unit comprising a body of sound and heat insulating material of relatively low structural strength, a relatively rigid expanded metal reinforcing element arranged adjacent each side of said body and each having portions offset inwardly toward and contacting with'said body to space the greater portions of the areas of said reinforcingi elements from said body, and a plurality of-fastening elements arranged at spaced points throughout said body and extending entirely therethrough, the end portions of said elements being looped around the inwardly oflset portions of the respective reinforcing elements for securing them to said body. 7 10. A building unit comprising a body of sound and heat insulating material of relatively low structuralstrength, a relatively rigid expanded metal reinforcing element arranged adjacent each side of said body and having the-greater portion of their areas arranged in spaced parallel relationship thereto, and a'plurality of fastening elements arranged at spaced points throughout said body and extending entirely therethrough, each of said fastening elements comprising a metallic shank having its intermediate portion projecting through said body, the end portions of said shanks being looped around portions of the respective reinforcing elements and having substantial portions of their extremities extending along and contacting with opposite faces of said body for substantially positively supporting said reinforcing elements with respect to said body in said parallel relationship.

In testimony whereof I aflix my signature.

' JOHN H. MAGEE. 

